Method and apparatus for debanding a compressible bundle

ABSTRACT

A method and apparatus for debanding a compressible bundle. The apparatus includes an End of Arm Tooling (EAT) component which is moved vertically downward over the bundle to a position where holding arms of the EAT component are manipulated to pick up and hold the bundle. At this position, one or more indenters of the EAT component are pressed into an upper surface of the bundle form a trough in the bundle that crosses under a band which surrounds the bundle. A cutting knife assembly of the EAT component is actuated to slide linearly along a longitudinal direction of the trough to cut the band without contacting the surface of the bundle, thereby enabling the band to drop away from the bundle. As a result, the bundle can be debanded without damaging the bags.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit under 35 U.S.C. §119(e) of U.S. Patent Application No. 61/183,249, entitled “Method and Apparatus for Debanding a Compressible Bundle,” filed Jun. 2, 2009, which is incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

This invention relates to a method and apparatus for removing a packaging band from a compressible bundle, and in particular, to a method and apparatus for cutting and removing the packaging band surrounding a bundle of bags, without damaging any of the bags.

BACKGROUND OF THE INVENTION

It is generally known in the manufacturing arts to package certain kinds of articles by stacking or rolling the articles together in a bundle, and securing the bundle by applying a band or other type of wrapper to an exterior surface of the bundle. For example, it is known in the container industry to prepare bundles of bags in bag rolls which are secured by paper, elastic and other types of bands. The bag rolls provide a convenient delivery package, for example, for delivering the bags in bulk to a packaging supplier, who in turn removes the bands and then repackages the bulk-delivered bags in containers for retail or commercial distribution of the bags. The bundled bags may be formed from a variety of materials, for example including plastics such as polyethylene, paper, woven and non-woven fabrics, and the like.

For example, a packaging supplier may receive bundles of polyethylene bags from an outside manufacturer that are provided in folded or rolled bundles each secured with a band. Bundles may be prepared with varying numbers of bags (for example, from 15 to 150 bags per bundle), and in varying widths (for example, from 4 inches to 20 inches wide). The bundles are typically packed in bulk cases for delivery to the packaging supplier.

At the packaging supplier's premises, the bundles are generally removed by hand from the cases so that the bands may be manually removed. Debanded bundles are then placed on a conveyor that conveys each bundle to a position where the bundle can be manually or automatically pushed into a chipboard or other type of paperboard carton or container, and then sealed. Alternatively, the debanded bundles may be packed by hand in the paperboard cartons or containers, and then hand-sealed.

Each of the manual processes used to process the bundles is inherently inefficient. However, automated processing can introduce a risk of damaging some of the bags, for example, during the debanding step.

Therefore, it would be advantageous to provide a method and apparatus which are capable of automatically processing the bundles without incurring a significant risk of damaging the contents of the bundles.

SUMMARY OF THE INVENTION

The present invention is directed to a method and apparatus for debanding a compressible bundle. In a preferred embodiment of the invention, an apparatus is configured to cut a band that surrounds a compressible bundle of polyethylene bags by driving one or more indenters into an outer surface of the compressible bundle, in a manner that depresses the surface of the compressible bundle to form a trough that crosses underneath a portion of the band. The apparatus then moves a cutting knife along a longitudinal direction of the trough to cut the band. As the cutting knife is being moved, it extends at least partially into the trough without contacting the surface of the bundle. As a result, cutting of the band is accomplished without risking damage to the bundle from the cutting operation.

The apparatus of the preferred embodiment may also preferably include a plurality of holding arms that are movable to contact and hold the compressible bundle in a stationary position to resist an insertion force of the indenters.

The cutting knife of the preferred embodiment comprises a cutting blade and a shoe. The shoe is positioned along a base portion of the cutting knife, thereby shielding the surface of the trough from exposure to the cutting knife. The shoe is also configured to receive and hold the band in a position suitable for cutting by the cutting blade.

The cutting knife is preferably actuated by a track actuator configured to move the cutting knife bi-directionally along the longitudinal direction of the trough. The cutting blade preferably includes cutting surfaces along each of opposing ends of the cutting knife in order to be capable of cutting the band when the cutting knife moves in either direction. In this configuration, the shoe preferably includes opposing ends each extending beyond one of the two cutting surfaces.

The apparatus of the preferred embodiment is configured to be movable in both horizontal and vertical directions. A first conveyor line may be used to sequentially deliver banded bundles to a debanding position where the apparatus operates to deband the bundle. After debanding the bundle, the apparatus preferably retains the debanded bundle via the holding arms, and is moved vertically and horizontally to a release position which may, for example, be positioned over a second conveyor line. The holding arms are then moved to release the debanded bundles onto the second conveyor line, which then delivers the released bags to a finishing area. The second conveyor line may optionally include buckets for receiving the bundle of bags. In this case, the apparatus may in addition preferably include a pusher for assisting in the release of the debanded bundle from the indentors and for depositing the debanded bundle in one of the buckets on the second conveyor line.

BRIEF DESCRIPTION OF THE DRAWINGS

The inventions will become more readily apparent from the Detailed Descriptions of the Invention, which proceeds with reference to the drawings, in which:

FIG. 1 shows a perspective view of an apparatus according to a first embodiment of the present invention;

FIG. 2 shows a top view of components of the apparatus of FIG. 1;

FIG. 3 shows a left view of the components of FIG. 2;

FIG. 4 shows an enlarged view of an End of Arm Tooling (EAT) component of the apparatus as depicted in FIG. 3;

FIG. 5 shows a partial front view of several of the components of FIG. 2, in which the EAT component is positioned in a pre-engagement position;

FIG. 6 shows a partial front view of components of FIG. 2, in which the EAT component is positioned in an engagement position;

FIG. 7 shows a perspective view of the components of FIG. 6 in the engagement position, as seen from the right, rear and top sides;

FIG. 8A shows a partial front view of the components of FIG. 5, modified according to a second embodiment of the present invention;

FIG. 8B show a right side view of the components of FIG. 8A;

FIG. 8C shows a partial perspective view of the components of FIGS. 8A, 8B as seen from the fight, rear and top sides, in which the EAT component is in a release position;

FIG. 9 shows a perspective view of a bundle of polyethylene bags having a trough as would be formed by the EAT component;

FIG. 10 shows a schematic block diagram of a control unit suitable for controlling the apparatus of FIG. 1, and its relation to a sequence of process steps for a method of operation according to the present invention;

FIG. 11 shows an alternative cutting knife assembly;

FIG. 12 shows the alternative cutting knife assembly of FIG. 11 in an End of Arm Tooling (EAT) component; and

FIG. 13 shows a perspective view of the components of FIG. 12 in an engagement position, as seen from the right, rear and top sides.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to a method and apparatus for debanding a compressible bundle, and in particular, for debanding a compressible bundle of bags (for example, polyethylene bags) which are banded (for example, with paper bands, rubber bands, polyethylene bands, or bands comprising any of a variety of other conventional band materials).

In a preferred embodiment of the invention, bundles of bags are arranged in a single-file grouping along a moving direction of a debanding conveyor line. Each bundle of bags is secured by a band that circumferentially surrounds a portion of the bundle. The bundles may be manually provided to the conveyor line, or may be provided to the debanding conveyor line by an intake system including a hopper that receives and sorts the bundles of bags before depositing the bundles either onto the debanding conveyor line, or onto accumulator conveyor line that is configured to accumulate and transfer the bundles to the debanding conveyor line.

The debanding conveyor line moves to progressively position each bundle successively in proximity to one or more End of Arm Tooling (EAT) components of the apparatus, each of which having a plurality of movable holding arms for holding and picking up the bundles. When a bundle reaches the EAT component, this component moves vertically downward over the bundle to an engagement position at which the arms can be manipulated to hold the bundle. At the engagement position, one or more indenters of the EAT component are pressed into an upper surface of the compressible bundle to form a trough in the upper surface. The indenters are configured to form the trough such that it crosses underneath the band that secures the bundle.

The EAT component further includes a cutting knife assembly, which is actuated to slide linearly along a longitudinal direction of the trough. A cutting blade portion of the cutting knife assembly extends at least partially into the trough, without contacting the indented surface of the bundle in the trough. The cutting knife assembly is actuated to slide linearly to a position at which it contacts and cuts the band.

After the band is cut, it falls to the debanding conveyor line so that it may be advanced by the debanding conveyor line to a removal station. The EAT component is moved vertically upward to lift the debanded bundle above the debanding conveyor line, and then horizontally to a release position over a table, bin or outflow conveyor line. Finally, it is either moved vertically downward or kept stationary as the holding arms are actuated to release the debanded bundle to a packaging station or subsequent conveyor line (for example, a bucket conveyor line) for further processing.

The features and advantages described briefly above and in more detail below are intended to be illustrative of principles of the present invention, and are not all-inclusive. Additional features and advantages will be readily apparent to one of ordinary skill in the art in view of the drawings, specification, and claims herein. Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and has not otherwise been selected to delineate or circumscribe the inventive subject matter. Accordingly, the invention is to be limited only by the scope of the claims and their equivalents.

FIG. 1 shows a perspective view of a debanding apparatus 100 according to a preferred embodiment of the present invention. As illustrated in FIG. 1, the debanding apparatus 100 includes a debanding conveyor line 120 surrounded by a framework 155 comprising cross-rails 157, gantry rails 156, and vertical rails 158. The debanding conveyor line 120 is preferably of a conventional design, and conveys banded bundles 110 toward an end of arm tooling (EAT) component 130, which is depicted for example in FIG. 2 at a debanding position 128 above the debanding conveyor line 120. With reference to FIGS. 3 and 4, the EAT component 130 as depicted comprises holding arms 133, indenters 134 and cutting knife assembly 135. The cutting knife assembly 135 includes a cutting blade 132 and a shoe 131.

Returning to FIG. 1, the apparatus 100 may optionally be provided with a hopper 101 for receiving and sorting bundles 110 for placement on an accumulator conveyor line 102 that accumulates and transfers the bundles 110 to the debanding conveyor line 120. The hopper 101 preferably places the bundles 110 sequentially onto the accumulator conveyor 102 in long edge leading (LEL) orientation.

FIGS. 2 and 3 further depict the debanding conveyor line 120 of the preferred embodiment as having moving belts 121, 122, 123 that move together sequentially. One of ordinary skill in the art will readily understand that the conveyor line 120 may be alternatively configured with any number of moving belts, including one moving belt. As illustrated for example in FIG. 2, the bundles 110 are preferably taken up on the debanding conveyor line 120 by dividers 129, which help to position the bundles 110 on the conveyor line 120 at a fixed spacing 124 (for example, at a between-bundle spacing of 9.375 inches).

As illustrated in FIGS. 2 and 3, slots 125, 126 are arranged between belt pairs 123, 122 and 122, 121, respectively. In order to grab one of the bundles 110, the EAT component 130 is laterally centered over belt 122 of the conveyor line 120. In this position, as illustrated for example in FIGS. 3 and 6, as the EAT component 130 moves vertically downward towards the debanding conveyor line 120, the holding arms 133 are able to extend into the slots 125, 126 for unencumbered movement.

FIG. 5 depicts the EAT component 130 of the preferred embodiment positioned vertically above the bundle 110 at the debanding position 128. Each indenter 134 is fixedly attached to a frame member 138 of the EAT component 130, and extends vertically downward to terminate at a probe portion 137 defining a lower end of the indenter 134. As illustrated in FIG. 6, for example, the probe portion 137 is configured to be pressed against an upper surface of the bundle 110 to form a trough 112 in the upper surface of the bundle.

Returning to FIG. 5, cutting knife assembly 135 extends downwardly from a track actuator 136, which is fixedly attached to the frame member 138. Arm actuating assemblies 139 are also each fixedly attached to the frame member 138, on opposing sides of each indenter 134 along a moving direction of the debanding conveyor line 120. The arm actuating assemblies 139 are configured to rotatably manipulate the holding arms 133, which may for example extend downwardly from a lower interior portion of each arm actuating assembly 139.

The arm actuating assemblies 139 each preferably include a mechanism (not shown) that actuates the arms 133 by moving a pin through a slot to in order to move the holding arms 133 rotatably inwardly or outwardly in the opposite direction. The pin is preferably actuated by an air cylinder or hydraulic cylinder. Alternatively, the holding arms 133 may be moved rotatably inwardly and outwardly by a motor driven actuator and associated gear mechanism of conventional design.

As configured, a lowest extent of the cutting knife assembly 135 (for example, shoe 131 as illustrated in FIG. 4) is movable through an interior cavity of the probe portion 137. In this configuration, no portion of the cutting knife assembly 135 extends beyond an exterior surface of the probe portion 137. As a result, when the trough 112 has been formed in a bundle 110 by the probe portion 137, the cutting knife assembly 135 can be moved by the track actuator 136 along the trough 112 without contacting any part of the surface of the bundle 110.

FIGS. 6 and 7 depict the EAT component 130 of FIG. 5 after it has been lowered at the debanding position 128. In this position, the EAT component 130 is lowered to a predetermined height h (as represented, for example, in FIG. 6 by a distance between a bottom surface of the frame 138 and an upper surface of the conveyor line 120) in order to drive the probe portion 137 to a desired depth into the top surface of the bundle 110 for forming the trough 112 as illustrated in FIG. 7. At the same time, the holding arms 133 are rotated inwardly by arm actuating assemblies 139 to secure the bundle 110 at opposing ends of the bundle 110.

Returning to FIG. 1, actuators 153 of a conventional design (for example, conventional stepper or servo motors) are positioned to move cross-rails 157 relative to gantry rails 156, and to move vertical rails 158 relative to cross-rails 157. This enables each EAT component 130 to be moved along X, Y, and Z axes. Alternatively, all or a portion of the framework 155 can be replaced by conventional industrial robots.

In the configuration illustrated in FIG. 1, the actuators 153 each preferably include a gearbox driven by a conventional stepper or servo motor for rotating a pulley that drives a belt which is attached to a carriage on an associated moving rail 157, 158. For the purposed of the present description, the X axis is parallel to a longitudinal centerline of the gantry rail 156, the Y axis is parallel to a longitudinal centerline of the cross-rail 157, and Z axis is parallel to a longitudinal centerline of the vertical rail 158.

FIG. 9 shows the banded bundle 110 alone the probe portion 137 has been driven into the top surface of the bundle 110 to form the trough 112. As can be seen in FIG. 8, the trough 112 extends underneath (and, in this case, is perpendicular to) the band 111.

As shown for example in FIGS. 4 and 7, the cutting knife assembly 135 is suspended from the track actuator 136 at a rest position laterally outside and adjacent to the inner cavity of rightmost probe portion 137. From this position, the cutting knife assembly 135 can be actuated by the track actuator 136 to move laterally through the inner cavity of the adjacent probe portion 137 and through the trough 112 toward the band 111.

The cutting knife assembly 135 is preferably attached to a carriage (not shown) that slides along linear rails enclosed inside of the of the track actuator 136. The carriage assembly, for example, may be pneumatically driven first in one direction to cut the band, driven on to an opposing rest position beyond the leftmost probe portion 137, held at this rest position until a subsequent debanding cycle is begun, driven pneumatically in the opposite direction to cut another band, and driven back to the initial rest position. In this manner, the cutting knife assembly 135 efficiently operates to cut bands bidirectionally.

In order to be operative in both directions, the shoe 131 and the cutting blade 132 are each configured with operating surfaces at each end of the cutting knife assembly 135. By operating the cutting knife assembly 135 bidirectionally, the number of movements of the cutting knife assembly that are required in order to process successive bundles 110 is effectively reduced by half.

While the carriage of track actuator 136 may preferably be pneumatically driven by a conventional air cylinder of suitable design, the carriage may also be alternatively driven by a conventional electric motor-driven actuator.

As the cutting knife assembly 135 moves to cut the band 111, the shoe 131 of the cutting knife assembly 135 (as illustrated, for example, in FIGS. 4 and 7) slides underneath the band 111 and preferably raises or maintains the band 111 in a current vertical position as is required for severing the band 111 with the cutting blade 132. The severed band 111 drops by gravity from the bundle 110 onto the debanding conveyor line 120.

After falling onto conveyor line 120, each band 111 may be carried to a downstream end 127 of the conveyor line 120 (for example, as illustrated in FIG. 2), where a waste bin (not illustrated) may be positioned to collect the severed bands 111 for later disposal.

After the band 111 has been removed, the EAT component 130 may be retracted vertically upward, retaining the bundle 110 by means of the holding arms 133, and moved horizontally to a position over an outflow conveyor line 140 as illustrated in FIGS. 1 and 8C.

As illustrated for example in FIG. 1, the outflow conveyor line 140 may preferably be configured with a plurality of buckets 141. In this case, the EAT component 130 is horizontally positioned over a selected one of the buckets 141. After reaching this position, the EAT component 130 is lowered vertically to a release position at which end portions of the holding arms 133 are positioned within the selected bucket. The holding arms 133 are then rotated outwardly by the arm actuating assemblies 139 to release the bundle 110 of bags into the selected bucket 141. Upon release, the bucket conveyor line 140 is free to deliver the bucket 141 and its contents to a high speed cartoner (HSC) or other suitable device for repackaging the bags.

Optionally, EAT component 130 may further include a pushing component 150 for pushing the bundle 110 into the selected bucket 141, as illustrated in FIGS. 8A-8C. With reference to FIGS. 8A and 8B, pushing components 150 are provided between and on opposing sides of the indenters 134 along the moving direction of the debanding conveyor line 120. Each pushing component 150 includes an actuator 152 which drives a piston 151, and is positioned so that a pushing surface of the piston 151 is positioned near an upwardly facing surface of the bundle 110 adjacent to the trough 112.

The pushers 150 are activated when the EAT component 130 reaches the release position and the holding arms 133 moved outwardly to release the bundle 110. Actuators 152 linearly move the pistons 151 so that the pushing surfaces of the pistons 151 push the bundle 110 into the bucket 141. As shown in FIGS. 8A-8C, the pushing components are aligned so that the linear movement of the pistons occurs with a plane defined by the X axis and Z axis, and at an acute angle to the Z axis. Other alternative mechanisms for pushing the bundle 110 off of the indenters 134 (for example, vibratory mechanisms and the like) are also contemplated within the scope of the present invention.

After the bundle 110 has been pushed into the bucket 141, the bucket conveyor line 140 moves the bucket 141 toward a packaging position for the bundle 110. For example, a packaging conveyor (not shown) may be positioned in parallel with the bucket conveyor line 140 so that a packing carton may be pulled down from a supply bin, placed on the packaging conveyor and positioned adjacent the bucket 141. The debanded bundle 110 may then be pushed into the adjacent carton, for example, by a conventional push palm device (not shown) operated by a mechanical rod timed by a cam follower bearing positioned in an adjacent trough. The carton is then sealed at each end by conventional means, and moved along the packaging conveyor to a position where it may be packed into a carton case and palletized.

FIG. 10 illustrates a schematic block diagram for a programmable logic controller (PLC) 1000 that is suitable for controlling the operation of the components described above in relation to the preferred embodiment of the present invention. The PLC 1000 is of a conventional design, as may be obtained for example from the General Electric Company of Schenectady, N.Y.

PLC 1000 includes a central processing unit (CPU) 1010 which is operated by a stored program and additional program instructions provided via a programming interface of the PLC 1000 (not shown). The stored program and program instructions are stored, for example, in a memory 1011.

A DC input module 1012 receives external inputs that instruct the CPU 1010 to regulate the PLC 1000. For example, the DC input module preferably receives inputs from a machine start switch 1028 to start operation of the debanding apparatus, and from a machine stop switch 1029 to stop operation of the apparatus. CPU 1010 directs operation of the apparatus via a 3-Axis Motion Control Module 1013 and a DC output module 1014. 3-Axis Motion Control Module 1013 is configured to instruct conventional servo drives 1023 that operate servo motors 1024 for moving the EAT component in each of the X, Y and Z directions. DC output module 1014 is configured to instruct DC drive unit 1021 and AC drive units 1022 to respectively drive DC motor 1025 and AC motors 1027 for operating the hopper 101 and conveyors 102, 120 and 140. The PLC 1000, drives 1021, 1022 and 1023, and motors 1024, 1025 and 1027, as well as other electrically-powered components of the debanding apparatus 100, are preferably powered either directly of indirectly by a conventional AC commercial power supply 1026.

FIG. 10 further illustrates a series of process steps 201-211 comprising a process 200 by which the debanding apparatus 100 may be operated by the PLC 1000.

At step 201 of the process 200 of FIG. 10, bundles 110 are received and sorted by engaging the DC motor 1025 to run the hopper 101 for placement on the accumulator conveyor 102. At step 202, the bundles 110 are placed on the accumulator conveyor 102, and a bundle aligner (not shown) of the accumulator conveyor 102 is activated by the DC output module 1014 to sequentially position the bundles 110 on the accumulator conveyor 102 in the long edge leading (LEL) orientation. The conveyor 102 is advanced by one of the AC motors 1027, which is activated by one of the AC drives 1022 and DC output module 1014.

At step 203, an air cylinder (not shown) of the accumulator conveyor 102 is activated by the DC output module 1014 to hold the bundles 1014 at a downstream end of the conveyor 102. At step 204, the air cylinder is operated to release one or more of the bundles 110 onto the debanding conveyor line 120. At step 205, the debanding conveyor 120 is indexed by another one of the AC motors 1027 activated by another one of the AC drives 1022 and DC output module 1014, in order to deliver one of the bundles 110 to the debanding position 128.

At step 206, the 3-axis motion control module 1013 instructs the servo drive 1023 controlling the motor 1024 which causes movement along the Z-axis to lower the EAT component 130 vertically, so that the indenters 134 are driven into an upper surface of the bundle 110 to form the trough 112. As described above, the indenters 134 are configured to form the trough 112 such that it crosses underneath the band 111. At step 206, the DC output module 1014 instructs the actuating assemblies 139 to rotate the holding arms 133 inwardly to hold and secure the bundle 110. The holding arms 133 are configured to hold the bundle 110 in a manner that resists an insertion force generated as the indenters 134 are driven into the upper surface of the bundle 110.

At step 207, the DC output module 1014 instructs the track actuator 136 to move the cutting knife assembly 135 from a rest position through the trough 112 toward the band 111. Upon reaching the band 111, the shoe 131 of cutting knife assembly 135 positions and/or holds the band 111 as it is severed by cutting blade 132 of the cutting knife assembly 135. The cutting knife assembly is thereafter moved to a corresponding rest position.

At step 208, the EAT component 130 is raised as it continues to hold the bundle 110, and is moved horizontally to a position over the second conveyor line 140. This movement is accomplished by the 3-axis motion control module 1013, which instructs the servo drives 1023 to operate the motors 1024 to move the EAT component upwardly in the Z-direction and in one or more of the X-direction and Y-direction.

At step 209, the 3-axis motion control module 1013 instructs the servo drive 1023 controlling the motor 1024 which causes movement along the Z-axis to lower the EAT component 130 to a release position over the second conveyor line 140. At step 210, the DC output module 1014 causes the holding arms 133 to be actuated by the actuating assemblies 139 to rotate outwardly to release and deposit the debanded bundle 110 either directly onto the second conveyor line 120, or into a bucket 141 if the outflow conveyor line 140 is so configured. Optionally, the DC output module 1014 further activates pushing components 150 to assist in releasing the debanded bundle 110, and instructs another AC drive 1022 to operate another motor 1027 to advance the outflow conveyor 140.

At step 211, the EAT Component 130 is raised and moved horizontally back to its previous position over the debanding position of the conveyor line 120. Once again, this movement is accomplished by the 3-axis motion control module, which instructs the servo drives 1023 to operate the motors 1024 to move the EAT component upwardly in the Z-direction and in one or more of the X-direction and Y-directions. At this point, the process returns to step 204, and another one of the bundles 110 of bags arrives via the conveyor line 120 at the debanding position 128.

FIG. 11 shows an alternative implementation of a cutting knife assembly 1135 that can be used, for example, in the debanding apparatus 100 of FIG. 1 in place of cutting knife assembly 135.

Cutting knife assembly 1135 includes a cutting blade 1132 and a shoe 1131. The shoe 1131 is contoured to define an angled leading edge that extends in a downward direction and terminates at a lower end 160 of the cutting knife assembly 1135. A plow portion 1162 is behind the lower end 160 of the cutting knife assembly 1135. A trough 1161 is located between the lower end 1160 of the cutting knife assembly 1135 and the plow portion 1162. The trough 1161 follows a bent path that terminates at a knife blade 1132 that is exposed inside the trough 1161 past the bend. The knife blade 1132 is configured so that it can cut a band passing through the trough.

FIG. 12 shows the cutting knife assembly 1135 of FIG. 11 coupled to an EAT component 1130 that is similar to the EAT component 130 shown in FIG. 4.

In FIG. 12 the cutting knife assembly 1135 extends downwardly from a track actuator, which is fixedly attached to a frame member. As configured, a lowest extent of the cutting knife assembly 135 (for example, lower end 1160 as illustrated in FIG. 12) is movable through an interior cavity of a probe portion of each indenter. In this configuration, no portion of the cutting knife assembly 1135 extends beyond an exterior surface of the probe portion. As a result, in a typical implementation, when a trough has been formed in a bundle by the probe portions, the cutting knife assembly 1135 can be moved by the track actuator 1136 along the trough 1112 (see FIG. 13) without contacting any part of the surface of the bundle.

FIG. 13 depicts the EAT component 1130 of FIG. 12 after it has been lowered at a debanding position. In this position, the EAT component 1130 is lowered to a predetermined height in order to drive the probe portion to a desired depth into the top surface of the bundle 1110 for forming a trough 1112. At the same time, the holding arms are rotated inwardly by arm actuating assemblies to secure the bundle at opposing ends of the bundle. After the probe portions have been driven to the desired depth, the cutting knife assembly 1135 resting at a home position will slide across, pushing down with the lower end 1131 of the cutting knife assembly 1135 any parts of the bags in the bundle 1110 that extend upward within the trough. This helps ensure that no portion of the bags gets caught up in the trough and/or gets accidentally cut by the knife blade 1132.

As the cutting knife assembly 1135 moves through the trough 1112, the angled leading edge and the lower end 1135 of the cutting blade assembly 1135 eventually contact the band 1111 that is securing the bundle 1110. The band 1111 is pushed down and around the lower end 1160 of the cutting blade assembly 1131 and enters the trough 1161, urged along at least in part by the plow 1162. The cutting knife assembly 1135 continues to advance through the trough and the band 1111 eventually reaches the knife blade 1132. The knife blade 132 cuts into and through the band 1111. The cutting knife assembly 1135 then returns to its home resting position.

In the illustrated implementation, the cutting knife assembly 1135 only cuts in one direction. In various implementations, the cutting knife assembly 1135 could be adapted to cut in two directions. Such implementations could include, for example, means to rotate the cutting knife assembly after it makes a cut in one direction. Alternatively, the cutting knife assembly 1135 could be adapted to include a second knife blade inside a second trough that opens in substantially the opposite direction as trough 1161.

Those skilled in the art will readily recognize additional numerous adaptations and modifications which can be made to the present invention which fall within the scope of the present invention as defined in the claims. For example, while the preferred embodiment was described with reference to a single EAT component moveably operated by a single 3-axis control module 1013, one skilled in the art will easily recognize that the invention may also be practiced with multiple EAT components 130 and multiple 3-axis control modules 1013.

It is intended that the scope of the present invention include all foreseeable equivalents to the elements and structures as described with reference to FIGS. 1-13. Accordingly, the invention is to be limited only by the scope of the claims and their equivalents. 

1. A method of operating an apparatus to cut a band that surrounds a compressible bundle, the method including the steps of: driving one or more indenters of the apparatus into an outer surface of the compressible bundle, thereby depressing the surface of the compressible bundle in a direction orthogonal to the surface to form a trough, the trough crossing underneath a portion of the band; moving a cutting knife of the apparatus along a longitudinal direction of the trough toward the band; and cutting the band with the cutting knife to deband the compressible bundle, wherein: a blade portion of the cutting knife extends at least partially into the trough in the orthogonal direction without contacting the surface of the bundle as it moves along the longitudinal direction.
 2. The method of claim 1, wherein the compressible bundle comprises a plurality of bags.
 3. The method of claim 2, wherein each one of the plurality of bags comprises a material selected from the group consisting of plastics, paper, woven fabrics and non-woven fabrics.
 4. The method of claim 1, wherein the band is selected from the group consisting of paper bands, rubber bands, elastic bands and polyethylene bands.
 5. The method of claim 1, further comprising the step of: moving a plurality of holding arms of the apparatus to contact the compressible bundle, the holding arms being configured to hold the bundle in a stationary position.
 6. The method of claim 1, wherein, after the cutting step, the method further comprises the steps of: moving the cutting knife to a rest position; and retracting the indenter from the compressible bundle.
 7. An apparatus for cutting a band that surrounds a compressible bundle, the apparatus comprising: a holding unit including a plurality of holding arms movable to hold and to release the compressible bundle; one or more indenters for depressing a portion of an outer surface of the compressible bundle to form a trough that underlies a portion of the band; and a cutting unit including: a cutting knife configured to extend at least partially within the trough; and an actuating unit which is configured to move the cutting blade along a longitudinal direction of the trough, without contacting the cutting blade against the outer surface of the compressible bundle.
 8. The apparatus of claim 7, wherein the compressible bundle comprises a plurality of bags.
 9. The apparatus of claim 8, wherein each one of the plurality of bags comprises a material selected from the group consisting of plastics, paper, woven fabrics and non-woven fabrics.
 10. The apparatus of claim 7, wherein the band is selected from the group consisting of paper bands, rubber bands, elastic bands and polyethylene bands.
 11. The apparatus of claim 7, wherein each of the holding unit, the one or more indenters and the cutting unit are affixed to a common framework.
 12. The apparatus of claim 7, wherein the cutting knife further comprises: a cutting blade; and a shoe, the shoe being positioned along a base portion of the cutting knife and configured for receiving and positioning the band for cutting by the cutting blade.
 13. The apparatus of claim 12, wherein: the actuating unit comprises a track actuator configured to move the cutting knife bi-directionally along the longitudinal direction; the cutting blade includes cutting surfaces along each of opposing ends of the cutting blade; and the shoe extends beyond each one of the cutting surfaces.
 14. The apparatus of claim 7, wherein the holding unit further comprises: a plurality of actuating assemblies configured to move the plurality of holding arms.
 15. The apparatus of claim 14, wherein the holding arms are movable within a plane that is orthogonal to the longitudinal direction of the trough.
 16. The apparatus of claim 7, wherein the apparatus further comprises a pusher for pushing the compressible bundle away from the indenters.
 17. The apparatus of claim 7, wherein the holding unit includes four actuating assemblies and four holding arms.
 18. The apparatus of claim 7, wherein the actuating unit which is configured to move the cutting blade from a rest position laterally displaced from one of the one or more indenters through an interior cavity of the one indenter and along the longitudinal direction of the trough.
 19. The apparatus of claim 7, further comprising: a debanding conveyor configured for moving the compressible bundle from a bundle receiving position to a bundle debanding position in proximity to the holding unit, the debanding conveyor including a plurality of conveyor belts configured to be driven synchronously with one another along parallel linear directions, wherein adjacent ones of the plurality of conveyor belts are spaced apart to form open separation slots, the separation slots being configured to enable unencumbered movement of the holding arms when the holding arms are positioned in proximity to the debanding conveyor and moved to hold the bundle.
 20. The apparatus of claim 19, wherein at least one of the plurality of conveyor belts includes a plurality of dividers sequentially positioned along the one belt, successive ones of the plurality of dividers being separated by a predetermined distance.
 21. A method of operating an apparatus to cut a band that surrounds a compressible bundle, the method including the steps of: providing the compressible bundle to a debanding conveyor; moving the compressible bundle via the first debanding conveyor line to a debanding position; positioning the apparatus in proximity to the compressible bundle at the debanding position; moving a plurality of holding arms of the apparatus to contact and hold the compressible bundle at the debanding position; driving one or more indenters of the apparatus into an outer surface of the compressible bundle, thereby depressing the surface of the compressible bundle in a direction orthogonal to the surface to form a trough crossing underneath a portion of the band; moving a cutting knife of the apparatus along a longitudinal direction of the trough toward the band, such that a blade portion of the cutting knife extends at least partially into the trough in the orthogonal direction without contacting the surface of the bundle; cutting the band with the cutting knife to deband the compressible bundle; moving the apparatus and the debanded bundle from the debanding position to a release position; and moving the plurality of holding arms of the apparatus to release the debanded bundle.
 22. The method of claim 21, wherein the compressible bundle comprises a plurality of bags.
 23. The method of claim 22, wherein each one of the plurality of bags comprises a material selected from the group consisting of plastics, paper, woven fabrics and non-woven fabrics.
 24. The method of claim 21, wherein the band is selected from the group consisting of paper bands, rubber bands, elastic bands and polyethylene bands.
 25. The method of claim 21, wherein the providing step further comprises the steps of: sorting a plurality of compressible bundles in a hopper; delivering at least one of the sorted bundles to an accumulator conveyor; and releasing the at least one sorted bundle by the accumulator conveyor to provide the compressible bundle to the debanding conveyor.
 26. The method of claim 21, further comprising the step of: moving the cutting knife to a rest position laterally displaced from the trough after the cutting step.
 27. The method of claim 21, wherein the debanded bundle is released onto an outflow conveyor.
 28. The method of claim 21, wherein the outflow conveyor is a bucket conveyor and the debanded bundle is released into a bucket on the bucket conveyor.
 29. The method of claim 21, wherein the step of moving the plurality of holding arms of the apparatus to release the debanded bundle further comprises the step of: pushing the debanded bundle from the apparatus into the bucket on the bucket conveyor. 